Ground screw foundation

Abstract

A telescoping ground screw foundation system for supporting electrical cabinets, EV charging stations, and utility enclosures. The system comprising an earth engaging pole having a helical screw or auger element configured to be driven into the earth, an first pole slidably received within the earth engaging pole in a telescoping relationship, and a foundation box mounted to the exposed upper end of the interior pole. The interior pole is adjustable relative to the earth engaging pole across a range of insertion depths to accommodate varying below-grade trench depths at the installation site, and is lockable in position using one or more locking elements. The foundation box is configured to sit at or flush with grade and provides a mounting interface for the above-grade equipment. The system facilitates rapid on-site assembly without poured concrete, is suitable for both temporary and permanent installations, and accommodates interchangeable foundation box configurations.

Description

GROUND SCREW FOUNDATIONCROSS REFERENCE TO RELATED APPLICATIONS

[0001] The application claims priority to U.S. Provisional Patent Application No.63 / 778.840, filed March 27, 2025, entitled 'GROUND SCREW FOUNDATION FOR EV CHARGING STATIONS,” of which is incorporated herein by reference in its entirety.FIELD OF THE INVENTION

[0002] This invention relates to underground foundations for outdoor cabinets and enclosures, and more particularly to an adjustable ground screw foundation that can be rapidly assembled and adjusted on-site to meet on-site requirements.BACKGROUND

[0003] The proliferation of electric vehicles ("EVs") has created substantial demand for EV charging infrastructure deployed across a wide variety of commercial and residential environments. As EV charging stations continue to be installed at scale, a reliable, durable, and cost-effective foundation system for supporting EV charging cabinets and related electrical enclosures has become increasingly important.

[0004] Similarly, outdoor utility cabinets are widely used in telecommunications, power distribution, fiber optic networking, street lighting, and other applications requiring aboveground access to buried service lines. These cabinets, sometimes referred to as conduit cabinets, house electrical and data connections, switching equipment, and other components that interface with underground utility lines. A reliable, level, and structurally sound foundation is required to support such cabinets and to provide a secure transition between the buried utility lines and the cabinet enclosure above grade.

[0005] Conventional approaches to mounting and grounding EV charging stations and similar utility cabinets rely on concrete pads or other fixed foundation systems. Under such conventional approaches, a form is typically constructed at the installation site, reinforcing steel is positioned within the form, and concrete is poured and allowed to cure before any above-grade equipment can be installed. This process requires extensive site preparation, significant labor, and considerable time to complete, thereby often delaying installation by37833983.1days or weeks depending on environmental conditions and local permitting requirements. In addition, concrete-based foundations are effectively permanent; once poured and cured, repositioning or removing the foundation requires significant demolition effort and expense. Concrete-based foundations also present significant logistical and environmental challenges. The installation of a concrete pad ty pically requires the delivery of heavy materials to the installation site, including ready-mix concrete, reinforcing steel, and formwork. In areas with limited access or constrained site conditions, such as parking structures, urban infill locations, or sites with congested underground utilities, the logistics of a concrete installation may be impractical or cost-prohibitive. Furthermore, concrete foundations are not well-suited to installations that may need to be relocated over time, as changes to parking lot layouts, site configurations, or electrical service requirements may necessitate the complete removal and reinstallation of the foundation system at substantial expense.

[0006] Another approach that has been employed in the industry involves the use of precast concrete foundation systems, in which a concrete base or pad is manufactured off-site and delivered to the installation location for placement. While pre-cast concrete systems can reduce some of the on-site labor associated with forming and pouring concrete in the field, they introduce their own set of significant challenges. Pre-cast concrete foundation units are inherently heavy and bulky, requiring specialized lifting and handling equipment for transport and placement. This adds logistical complexity and cost to the installation, particularly in constrained site environments such as parking garages or locations with limited vehicle access. Moreover, pre-cast concrete foundations are manufactured to fixed dimensions and geometries, providing no means of adjustment to accommodate site-specific conditions such as varying soil elevations, uneven grade, or differing below-grade conduit configurations. Like their poured-in-place counterparts, pre-cast concrete foundations are also effectively permanent once placed, making relocation or removal difficult and expensive.

[0007] A further limitation common to all conventional concrete-based foundation systems, whether poured-in-place or pre-cast, is their inability to readily accommodate the varying below-grade trench depths required for electrical service connections. Electrical installations for EV chargers and similar cabinet-mounted equipment typically require below-grade conduit trenching, and the depth of such trenches can vary significantly- depending on local electrical codes, soil conditions, and site-specific requirements. Trench depths may range from as shallow as six inches to as deep as twenty-four inches or more.137833983.1Because concrete foundations are cast in a fixed form prior to equipment installation, they do not provide structural flexibility to accommodate this variable range of trench depths. Adapting a conventional concrete foundation to a non-standard or site-specific trench depth typically requires custom modification of the formwork and reinforcement prior to the pour, adding further complexity7, labor, and cost to the installation process.

[0008] Accordingly, there exists a need in the art for an improved foundation system for EV charging stations and utility cabinets that overcomes the limitations of conventional concrete foundations, that is adjustable across a range of trench depths, that allows for flushgrade mounting of the enclosure or junction box, is easily assembled and adjusted on site, and is compatible with surrounding concrete encasement for added structural integrity.BRIEF SUMMARY

[0009] The present disclosure relates to a foundation system and methods of installing the same. In one aspect, the foundation system comprises a first pole, a second pole, at least one locking element, and a foundation box. The first pole comprises a first end, a second end, and a middle portion connecting the first end and the second end. The second pole likewise comprises a first end, a second end, and a middle portion connecting the first end and the second end. At least a portion of the second pole comprises an external helical screw element configured to engage surrounding soil when the second pole is rotated into the earth. The first end of the second pole defines an opening configured to receive the first pole, such that the first pole is configured to be adjustably disposed within the second pole. The at least one locking element is configured to fix the relative position of the first pole with respect to the second pole, and the foundation box is connected to the first end of the first pole.

[0010] In various embodiments, the second pole comprises one or more locking apertures formed through a wall of the second pole. The at least one locking element may comprise a thumb screw, a machine screw, a bolt, a locking pin, or a spring-loaded detent pin received through the one or more locking apertures to engage the first pole. The first pole may comprise one or more engagement features positioned along its length and configured to cooperate with the at least one locking element. In certain embodiments, the first pole comprises a retention feature at or near its second end configured to prevent the first pole from being withdrawn entirely from the second pole, and the system may further comprise a biasing element within the second pole.

[0011] In some embodiments, the first pole and the second pole are connected through a threaded engagement. The foundation system may further comprise one or more interior 237833983.1poles nested within the second pole. The first pole, the second pole, or both, may comprise one or more openings formed through a wall thereof. In certain embodiments, the first pole and the second pole have complementary non-circular cross-sections. The first pole and the second pole may be configured to provide an electrical ground path between the earth and an electrical cabinet, an EV charging station, or a utility7enclosure.

[0012] The foundation box may be secured to the first end of the first pole by a pole mounting element comprising a threaded connection, a slip-fit engagement secured by fastening screws or bolts, or a ratcheting system that tightens around the first end of the first pole. The foundation box may comprise a base, a plurality7of sidewalls defining an interior cavity, and a removable mounting platform secured to the base and sidewalls. The mounting platform is configured to provide a mounting surface for an electrical cabinet, an EV charging station, or a utility enclosure. The foundation box may further comprise one or more conduit entry and exit openings formed through the sidewalls or the mounting platform. In some embodiments, the foundation box is configured to be interchangeably connectable to the first pole and the second pole.

[0013] At least one of the first pole and the second pole may be provided with a corrosion-resistant coating or treatment comprising hot-dip galvanization, electroplated zinc coating, epoxy powder coating, fusion-bonded epoxy lining, or thermoplastic coating.

[0014] In another aspect, the present disclosure provides a method of installing a foundation system for an above-grade electrical cabinet, EV charging station, or utility enclosure. The method comprises driving a second pole into the earth at an installation site by applying rotational torque to the second pole. The second pole has a first end with an opening, a second end, and at least a portion comprising an external helical screw element that engages surrounding soil as the second pole is rotated. The method further comprises inserting a first pole into the opening at the first end of the second pole after the second pole has been advanced to a desired below-grade depth, adjusting the first pole relative to the second pole to a predetermined height, and securing the first pole in position relative to the second pole at the predetermined height using at least one locking element. A foundation box is then mounted to a first end of the first pole. In certain embodiments, the method further comprises introducing concrete or grout material into an annular space surrounding the second pole below grade.BRIEF DESCRIPTION OF THE DRAWINGS337833983.1

[0015] Various aspects of at least one example are discussed below with reference to the accompanying figures, which are not intended to be drawn to scale. The figures are included to provide an illustration and a further understanding of the various aspects and are incorporated in and constitute a part of this specification but are not intended as a definition of the limits of any particular example. The drawings, together with the remainder of the specification, serve to explain principles and operations of the described and claimed aspects. In the figures, each identical or nearly identical component that is illustrated in various figures is represented by a like numeral.

[0016] FIG. 1 shows a top perspective view of an example embodiment of a foundation with aspects disclosed herein.

[0017] FIG. 2 shows a side perspective view with a view cutout of an example embodiment of a foundation with aspects disclosed herein.

[0018] FIG. 3 shows a side perspective view of an example embodiment of a foundation with aspects disclosed herein.

[0019] FIG. 4A-4C show a side perspective view of example embodiments of a foundation with aspects disclosed herein.

[0020] FIG. 5 shows a top perspective view of an example embodiment of a foundation with aspects disclosed herein.

[0021] FIG. 6 shows a bottom perspective view of an example embodiment of a foundation with aspects disclosed herein.

[0022] FIG. 7 shows a side perspective view of an example embodiment of a foundation with aspects disclosed herein.

[0023] FIG. 8 shows a top perspective view of an example embodiment of a foundation box with aspects disclosed herein.

[0024] FIG. 9 shows a bottom perspective view of an example embodiment of a foundation box with aspects disclosed herein.

[0025] FIG. 10 shows a side perspective view of an example embodiment of a foundation with aspects disclosed herein.

[0026] FIG. 11A-11B shows a side perspective view of an example embodiment of a foundation with aspects disclosed herein.

[0027] FIG. 12 shows a side perspective view of an example embodiment of a foundation with aspects disclosed herein.

[0028] FIG. 13 shows a side perspective view of an example embodiment of a foundation with aspects disclosed herein.437833983.1

[0029] FIG. 14 shows an example method of installation of an example embodiment of a foundation with aspects disclosed herein.DETAILED DESCRIPTION

[0030] To address the deficiencies of conventional poured-in-place and pre-cast concrete foundation systems described above, ground screws and helical augers have been explored as an alternative means of anchoring above-grade structures such as EV charging stations and electrical cabinets. A ground screw or helical auger is a steel shaft with one or more helical flights or screw threads that is driven or torqued directly into the earth using mechanical installation equipment. Because the ground screw is installed by rotation into the soil rather than by excavation and concrete placement, its installation requires no formwork, no curing time, and significantly less on-site labor than a conventional concrete foundation. Ground screws can generally be installed in a fraction of the time required for a concrete pad, and can, in many implementations, be removed and reinstalled at a different location if site conditions change, a significant practical advantage over permanent concrete foundations. Furthermore, because ground screws do not require the delivery of heavy concrete materials to the site, they are better suited for installations in constrained or logistically challenging environments.

[0031] Despite these advantages, ground screw and helical auger foundation products have their own significant limitations that have hindered their widespread adoption for EV charger and utility cabinet installations. In particular, existing ground screw foundation products do not provide any meaningful adjustability to accommodate varying below-grade trench depths at a given installation site. Because the depth of a below-grade electrical conduit trench can vary considerably from site to site, ranging from as shallow as six inches to as deep as twenty-four inches or more depending on local electrical codes and site conditions, a ground screw foundation of fixed geometry may not align properly with the above-grade enclosure mounting points when installed at a site with a non-standard trench depth. Installers faced with this limitation are typically forced to either accept a non-optimal installation configuration, modify the ground screw hardware in the field using tools and techniques not sanctioned by the manufacturer, or forego the use of a ground screw foundation altogether in favor of a more adaptable, but more labor-intensive, concrete solution. Because of these limitations, ground screw foundations do not provide an integrated means for mounting a flush-grade junction box or conduit enclosure at the base 537833983.1of the EV charging cabinet, further limiting their utility in electrical installations that require a clean and code-compliant transition between the below-grade conduit and the above-grade equipment.

[0032] The present disclosure addresses the above limitations by providing a telescoping ground screw foundation system 100 that combines the ease-of-installation benefits of a ground screw foundation with an adjustable telescoping feature that accommodates a wide range of below-grade trench depths. In accordance with embodiments of the present invention, the foundation system 100 comprises a ground screw that is driven into the earth at the installation site, a steel pole that slides telescopically within the ground screw and is secured at the desired height using set screws, and a foundation box mounted to the upper end of the steel pole that can sit flush with grade and accommodate the pouring of concrete around it for additional structural integrity. This telescoping arrangement allows the foundation system 100 to be configured on-site to match the specific trench depth encountered, without the need for field modification of the primary structural components, thereby providing a faster, more flexible, and more cost-effective foundation solution than either conventional concrete foundations or prior art fixed-geometry ground screw systems.

[0033] Referring to FIGs. 1-12 the telescoping ground screw foundation system 100 comprises at least three components: a foundation box 110, an first pole 120, and an earth engaging pole 130 (a second pole). The earth engaging pole 130 is configured to function as the primary earth-engaging element and comprises the screw or auger portion 139 of the ground screw foundation system 100. The first pole 120 is sized and configured to be slidably received within the hollow interior of the earth engaging pole 130, such that the first pole 120 can be extended or retracted relative to the earth engaging pole 130 to achieve a desired effective height and thereby accommodate the below-grade trench depth at the installation site. The foundation box 110 is mounted to the first end 121 of the first pole 120 and is configured to sit flush with, or at, grade level, providing a mounting platform 111 for the EV charging station, electrical cabinet, or utility enclosure to be supported by the ground screw foundation system 100.

[0034] The three-component architecture of the ground screw foundation system 100 is specifically designed to facilitate on-site assembly without the need for specialized tools, pre-formed excavation, or poured concrete. In a typical installation sequence, the earth engaging pole 130 is first driven or torqued into the earth at the selected installation location using conventional mechanical installation equipment. Once the earth engaging pole 130 has been advanced to the desired below-grade depth, the first pole 120 is inserted into an 637833983.1opening 134 disposed on the first end 1 of the earth engaging pole 130 and extended to the appropriate height to account for the site-specific trench depth. The first pole 120 is then locked in position relative to the earth engaging pole 130 using any suitable locking mechanism 135, as further described herein. Finally, the foundation box 110 is secured to the first end 121 of the first pole 120, completing the assembly of the ground screw assembly 100.

[0035] For ease of viewing, FIG. 2 illustrates a cut away view of the earth engaging pole 130, showing the second end 123 of the first pole 120 disposed within the earth engaging pole 130 during assembly.

[0036] Referring to FIGs. 3-6, the earth engaging pole 130 is an elongated structural member having a first end 131 and a second end 133 connected together by a middle portion 132. The first end 131 ofthe earth engaging pole 130 defines an opening 134 configured to receive the first pole 120 in a slidable, telescoping relationship. The second end 133 of the earth engaging pole 130 is configured for engagement with the earth and, in some embodiments, is pointed or otherwise tapered to facilitate penetration into the ground during installation. At or near the second end, the earth engaging pole 130 comprises at least one helical flight, screw thread, or auger element 139 formed on or attached to the outer surface of the pole, which engages the surrounding soil as the earth engaging pole 130 is rotated and driven downward, providing a secure below-grade anchor for the ground screw foundation system 100.

[0037] Referring to FIGs. 4 A-4C, near the first end 131 of the earth engaging pole, one or more locking apertures 136 are provided through the wall of the earth engaging pole 130. These locking apertures 136 are configured to receive a locking element 135 that engages the inserted first pole 120 and restricts its longitudinal displacement relative to the earth engaging pole 130. Suitable locking elements 135 include, without limitation, thumb screw s, machine screws, bolts and nuts, locking pins, spring-loaded detent pins, or any other fastening device capable of fixing the relative positions of the first pole 120 and earth engaging pole 130. In some embodiments, the first pole 120 may similarly comprise one or more apertures, channels, or other engagement 124 features positioned along its length to receive or cooperate with the locking elements 135, thereby providing discrete, repeatable locking positions that correspond to standard trench depths commonly encountered in the field.

[0038] In certain embodiments, the first end 131 of the earth engaging pole 130 may be disposed within and received by the second end 123 of the first pole 120, such that the screw 737833983.1or auger portion 139 is located at the lowermost extent of the assembled ground screw foundation system 100. In this configuration, the earth engaging pole 130 may comprise a ledge, ridge, flange, or other structural feature at or near its upper end that serves to support the weight of the pole or poles nested above it and to limit the downward travel of the first pole 120 relative to the earth engaging pole 130. The poles in this configuration are likewise secured in position using screws, bolts, locking pins, or equivalent fastening means, similar to the first embodiment described above. In some embodiments, the auger portion 139 extends from the first end 131 of the earth engaging pole 130 to or past the middle portion 132.

[0039] In some embodiments, the first pole 120 is an elongated structural member having a first end 121 connected to a second end 123 by a middle portion 122. The first end 121, or upper end, of the first pole 120 is the end that projects above the first end of the earth engaging pole 130 when the ground screw foundation system 100 is assembled and installed, and to which the foundation box 110 is secured. The second end 123 of the first pole 120, referred to herein as the hidden end or lower end, is the end that is disposed within the interior of the earth engaging pole 130 when the ground screw foundation system 100 is assembled.

[0040] The first pole 120 is dimensioned such that it is slidably received within the earth engaging pole 130 across a range of insertion depths, enabling the effective height of the ground screw foundation system 100 to be adjusted on-site to match the depth of the below-grade electrical conduit trench. For example, in one embodiment suitable for typical EV charger and utility cabinet installations, the earth engaging pole 130 may have an outer diameter or outer cross-sectional dimension of approximately four inches to six inches, a wall thickness of approximately one-eighth inch to one-quarter inch, and an overall length of approximately thirty-six inches to sixty inches, with the helical auger element 139 having a flight diameter of approximately six inches to twelve inches. The first pole 120, which is received within the earth engaging pole 130, may have an outer diameter or outer cross-sectional dimension of approximately three inches to five inches, sized to provide a close sliding fit within the inner bore of the earth engaging pole 130, a wall thickness of approximately one-eighth inch to three-sixteenths inch, and an overall length of approximately twenty-four inches to forty-eight inches. The telescoping overlap between the first pole 120 and the earth engaging pole 130 in this configuration provides a usable adjustment range of approximately six inches to twenty -four inches, which is sufficient to837833983.1accommodate the range of below-grade conduit trench depths most commonly encountered in the field.

[0041] It will be appreciated that the foregoing dimensions are provided by way of illustration only and are not intended to limit the scope of the present invention. Larger-diameter pole configurations, for example, an earth engaging pole 130 having an outer cross-sectional dimension of eight inches or more and a first pole 120 having an outer cross-sectional dimension of six inches or more, may be employed in applications requiring greater structural load capacity, such as installations supporting heavy utility cabinets, multi -unit EV charging islands, or installations in areas subject to high wind loads or vehicular impact. Larger-diameter poles provide increased section modulus and moment of inertia, resulting in greater resistance to lateral bending forces and improved overall structural rigidity of the assembled ground screw foundation system 100. The helical auger element 139 on larger-diameter earth engaging poles 130 may similarly be increased in flight diameter, for example, to fourteen inches or more, to provide greater bearing area against the surrounding soil and correspondingly higher axial and lateral load capacity.

[0042] Conversely, smaller-diameter pole configurations, for example, an earth engaging pole 130 having an outer cross-sectional dimension of approximately two and one-half inches to three and one-half inches and a first pole 120 having an outer cross-sectional dimension of approximately two inches to three inches, may be employed in lighter-duty applications, such as installations supporting small single-unit EV chargers, telecommunications pedestals, or fiber optic splice enclosures, where the imposed structural loads are relatively modest and a smaller, more lightweight foundation system is desirable for ease of transport and installation. Smaller-diameter configurations further reduce the size of the pilot hole or starter excavation required at the installation site and may be installed using smaller, lighter mechanical drive equipment, which can be advantageous in constrained site environments.

[0043] The wall thickness of the first pole 120 and the earth engaging pole 130 may also be varied independently of the outer cross-sectional dimensions to address specific performance requirements. Thicker-walled poles provide increased structural strength, greater resistance to local buckling at the locking apertures 136, and improved durability against corrosion-related material loss over the sendee life of the installation, but at the cost of increased weight and material expense. Thinner-walled poles provide a lighter and more cost-effective assembly that may be sufficient for lighter-duty or temporary’ installations where long-term corrosion exposure is not a primary concern. In all configurations, the wall 937833983.1thickness and cross-sectional dimensions of the first pole 120 and the earth engaging pole 130 are preferably selected in combination to ensure that the annular clearance between the outer surface of the first pole 120 and the inner surface of the earth engaging pole 130 is sufficiently small to minimize lateral play and maintain structural alignment between the poles, while still permitting smooth longitudinal sliding adjustment throughout the full range of telescoping travel.

[0044] In some embodiments, the first pole 120 is configured to telescope from a fully collapsed position, in which the first pole 120 is substantially fully retracted within the earth engaging pole 130, to a fully extended position, in which the first pole 120 is advanced to its maximum extension relative to the earth engaging pole 130. To prevent the first pole 120 from being inadvertently withdrawn entirely from the earth engaging pole 130 during adjustment or use, the first pole 120 may be provided with a retention feature at or near its second end 122, such as an enlarged end portion, a flange, a collar, a transverse pin, or one or more radially extending projections, that engages an internal shoulder, ledge, or stop feature within the earth engaging pole 130 to arrest the outward travel of the first pole 120 at the limit of its extension.

[0045] In some embodiments, the first pole 120 is configured to telescope from a fully collapsed position, in which the first pole 120 is substantially fully retracted within the earth engaging pole 130, to a fully extended position, in which the first pole 120 is advanced to its maximum extension relative to the earth engaging pole 130. To prevent the first pole 120 from being inadvertently withdrawn entirely from the earth engaging pole 130 during adjustment or use, the first pole 120 may be provided with a retention foot 125 at or near its second end 123, such as an enlarged end portion, a flange, a collar, a transverse pin, or one or more radially extending projections, that engages an internal shoulder, ledge, or stop feature within the earth engaging pole 130 to arrest the outward travel of the first pole 120 at the limit of its extension.

[0046] Referring to FIGs. 11A-11B, in some embodiments the first pole 120 and the earth engaging pole 130 may be provided as a pre-assembled, integrated telescoping unit in which the first pole 120 is disposed within the earth engaging pole 130 prior to delivery to the installation site. In this configuration, the first pole 120 is retained within the earth engaging pole 130 by a retention foot 123 disposed at or near the second end 123 of the first pole 120. The retention foot 123 comprises an enlarged end portion, a radially extending flange, a collar, or one or more outwardly projecting tabs that are dimensioned to be larger than the opening 134 at the first end 132 of the earth engaging pole 130, thereby preventing 1037833983.1the first pole 120 from being withdrawn entirely from the earth engaging pole 130 during telescoping extension. When the ground screw foundation system 100 is in its collapsed or transport configuration, the first pole 120 is fully or partially retracted within the earth engaging pole 130, with the retention foot resting on or near an internal shoulder, ledge, or the closed second end 133 of the earth engaging pole 130, resulting in a compact, singleunit assembly that is readily transportable to the installation site.

[0047] To deploy the ground screw foundation system 100 at the installation site, the installer drives the earth engaging pole 130 into the ground to the desired depth and then draws the first pole 120 upward out of the earth engaging pole 130 to the desired extension height, at which point the first pole 120 is locked in position using the locking elements 135 as described herein. In some embodiments, a biasing element 140 such as a compression spring, a gas spring, or an elastomeric spring is disposed within the interior of the earth engaging pole 130 beneath the second end 123 of the first pole 120. The biasing element exerts an upward force on the second end 123 of the first pole 120, urging the first pole 120 toward its extended position and thereby assisting the installer in telescoping the first pole 120 out of the earth engaging pole 130 during deployment. The locking elements 135 can be used here to lock the first pole 120 within the earth engaging pole 130 during transport or installation. For example, after installation or deployment, the user can remove a locking pin that held the first pole 120 in place and extend the first pole 120.

[0048] The biasing element reduces the manual effort required to extend the first pole 120, which may be particularly advantageous when the ground screw foundation system 100 is installed in the field by a single installer or when the weight of the first pole 120 and attached foundation box 110 would otherw ise make manual extension difficult. The spring force of the biasing element is preferably selected to assist in extension of the first pole 120 without being so great as to cause the first pole 120 to extend uncontrollably when the locking elements 135 are released. In embodiments without a biasing element, the first pole 120 is extended manually by the installer and held in position while the locking elements 135 are engaged.

[0049] In some embodiments, the ground screw foundation system 100 may comprise a plurality of pole sections, wherein two or more first pole 120 of progressively smaller cross-section are nested concentrically within one another, each slidably received within the next larger pole section. In other embodiments, the pole sections are nested within the earth engaging pole 130. where the plurality of poles are not removal from the earth engaging pole 130, similar to the embodiment of FIG. 11. These multi-stage telescoping configuration 1137833983.1enables the ground screw foundation system 100 to accommodate an even greater range of below-grade trench depths than would be achievable with a single-stage assembly, and may be particularly advantageous in installations with unusually deep conduit trenches or other non-standard below-grade configurations. The sections can be locked into place using locking pins, bolts, screws, thumb screws, or the like.

[0050] In certain embodiments, the connection between the first pole 120 and the earth engaging pole 130 may be achieved through a threaded engagement, wherein the first pole 120 is configured to be threaded or screwed into the earth engaging pole 130 using complementary helical threads formed on the respective mating surfaces of the two poles. This threaded engagement provides a strong and positive mechanical connection between the poles while simultaneously enabling fine adjustment of the effective height of the ground screw foundation system 100 by rotation of the first pole 120 relative to the earth engaging pole 130.

[0051] In some embodiments, the foundation box 110 is mounted to the first end 121 of the first pole 120. In other embodiments where the trench depth is shallow and / or the first pole 120 is not required, to the first end 131 of the earth engaging pole 130 directly. The foundation box 110 is a structural enclosure configured to sit at or flush with grade level and to provide a mounting interface between the telescoping pole assembly below grade and the EV charging station, electrical cabinet, or utility enclosure above grade. The foundation box 110 may be fabricated from any suitable material providing adequate strength, durability, and weather resistance, including without limitation cast iron, fabricated steel, aluminum, high-density polyethylene, fiber-reinforced polymer, or other engineering plastics.

[0052] Referring to FIG. 7, the foundation box 110 is not limited to any particular external geometry and may be configured in any shape suitable for the intended application, including rectangular, square, circular, polygonal, or custom profiles. In some embodiments, the foundation box 110 is 24 inches by 12 inches, or 12 inches by 12 inches. The foundation box 110 comprises a base 101 and a plurality of sidewalls 102 defining an interior cavity, and may further comprise a mounting platform 111.

[0053] Referring to FIGs. 8-9, The foundation box 110 is secured to the upper end of the first pole 120, or earth engaging pole 130, as applicable, by any suitable means. In a first embodiment, the foundation box 110 comprises a pole mounting element 114. The pole mounting element 114 is configured to secure the foundation box 110 to the first end 121 of the first pole 120 or the first end 131 of the earth engaging pole 130. In some embodiments,1237833983.1the pole mounting element 114 is configured to slidably engage the first end 121 of the first pole 120. The mounting element 114 comprises holes or apertures configured to allow for locking pins, screws, bolts, or the like to secure the first end 121 of the first pole 120 to the foundation box 110.

[0054] In other embodiments, the foundation box 110 may be secured directly to the pole by a threaded connection, wherein the upper end of the first pole 120 with an external or internal thread, and a corresponding pole mounting element 114 could comprise a threaded receiver or socket formed in the base of the foundation box 110. Where the threaded receiver or socket is configured to threadably engage the pole end, allowing the foundation box 110 to be screwed directly onto the first end of the first pole 120 or the earth engaging pole assembly to achieve a strong, positive, and rotationally secure connection without the need for supplemental fasteners.

[0055] In some embodiments, for example as illustrated in FIG. 7, the foundation box 110 is mounted directed to the earth engaging pole 130, i.e., without the first pole 120 disposed between. This arrangement can be especially useful when the depth required for the foundation is shallow, or it may be difficult to position the earth engaging pole 130 deep into the ground due to various constraints. For example, if it too difficult to advance the earth engaging pole 130 any further into the ground, there is a know n hazard or shallow utility line the user wants to avoid, or if the foundation depth requirement is shallow and the depth is achieved using only the engaging pole 130.

[0056] In another embodiment, the foundation box 110 may be connected to the first pole 120 or earth engaging pole 130 by means of an intermediate pivotable connector that is interposed betw een the top of the pole assembly and the base of the foundation box 110. This pivotable connector is configured to permit angular adjustment of the foundation box 110 relative to the longitudinal axis of the pole, allowing the foundation box 110 to be tilted, rotated, or otherwise reoriented to achieve a level orientation even where the pole has been installed at a slight angle from vertical due to site soil conditions or installation variability. In preferred embodiments, the pivotable connector comprises a ball-and-socket joint, a universal joint, or an equivalent articulating interface, with one or more locking fasteners such as set screws or clamping bolts that, once the desired orientation has been achieved, are tightened to fix the angular position of the foundation box 110 relative to the pole and prevent further pivoting movement. In some embodiments, the foundation box 110 comprises leveling screws for the mounting platform 111. That is, the foundation box 110 can sit unlevel, but the mounting platform Il l is leveled using said leveling screws. In other 1337833983.1embodiments, leveling screws or adjustments can level the foundation box 110 when the first pole 120 or second pole 130 is not level. For example, the foundation box 110 can be able to level up to and including a 10 degree off zero bubble.

[0057] In some embodiments, the pole mounting element 114 comprises an internal connector or receiver configured to engage the top of the pole assembly by means of a threaded connection, a slip-fit engagement secured by fastening screws or bolts, or a combination thereof. The connection between the foundation box 110 and the pole may further be configured to permit adjustment of the angular orientation and pitch of the foundation box 110 relative to the pole assembly, enabling the foundation box 110 to be leveled independently of the pole even where the pole is not perfectly plumb following installation, by means of screw or bolt adjustments at the pole-to-box interface.

[0058] In other embodiments, the pole mounting element 114 is configured with threads that engage threads of the first end 121 of the first pole 120. That is, the foundation box 110 can be screw ed or twisted onto the first end 121 of the first pole 120. In other embodiments, the pole mounting element 114 comprises a ratcheting system that tightens around the first end 121 of the first pole 120. The pole mounting element 114 can have a hole at the upper most part to allow for access to the first pole 120.

[0059] The mounting platform 111 can be used as a removable top or cover that is secured to the base 112 and sidewalls 113 by screws, bolts, adhesive, snap-fit fasteners, or any other suitable retention means. The mounting platform 111 facilitates access to the interior of the foundation box 110 during installation, wiring, or subsequent service and maintenance operations, and allow s for the mounting of the utility cabinet, enclosure, EV charger, or the like.

[0060] Referring to FIG. 9, the foundation box 110 further comprises one or more conduit entry and exit openings 115 formed through the sidewalls and / or the top of the box, through which electrical conductors, conduit, and other utility connections may be routed between the below-grade conduit system and the above-grade mounted equipment. These openings 115 may be formed as pre-cut apertures, knockouts, or threaded conduit hubs, and may be located on any one or more of the sides or top of the foundation box 110 as required by the installation configuration.

[0061] The ground screw7foundation system 100 is further designed to enable interchangeability of different foundation box 110 configurations on the same telescoping screw base assembly 100. That is. the foundation box 110 connects to the telescoping ground screw assembly 100 and may be exchanged or substituted for a different foundation box 1101437833983.1configuration depending on the application, the mounted equipment type, or the site-specific installation requirements, without the need to disturb or reinstall the below-grade pole assembly. In other words, the ground screw assembly 100 can be installed and used with one foundation box 110. After some time, the foundation box 110 can be replaced with a different foundation box 110 to facilitate a different enclosure or to replace a broken foundation box 110 without the need to redo the entire foundation system. Something that is not possible when using concrete foundations.

[0062] The foundation box 1 10 and mounting platform 111 may be sealed and rendered w aterproof using any suitable means, including gasketing, sealant, potting compound, heatshrink encapsulation, or other w eatherproofing techniques, to protect the internal wiring and connections from ingress of water, dust, and other environmental contaminants.

[0063] It will be appreciated that the scope of the present invention is not limited to a box-shaped or enclosed mounting element. Referring to FIG. 12, in certain embodiments, the foundation box 110 may be replaced with a mounting plate 210, e.g., a flat foundation plate, mounting flange, or bracket, that is secured to the first end 121 of the first pole 120 or the first end 132 of the earth engaging pole 130 and that provides a planar mounting surface at or above grade for direct attachment of the EV charging station, electrical cabinet, or utility enclosure. The mounting plate 210 may comprise a flat steel, aluminum, or polymer plate having a plurality of mounting holes or slots arranged in a pattern corresponding to the bolt pattern of the above-grade equipment, and may be welded, bolted, or threadably secured to the top of the pole assembly. In some embodiments, the mounting plate 210 is welded directly to the first end 121 of the first pole 120. Attaching the mounting plate 210 to the first pole 120 can be done at the installation site, or in the factory', prior to installation.

[0064] In other embodiments, the foundation box 110 and any intermediate mounting element may be omitted entirely, and the first end 121 of the first pole 120, or, in configurations where the first pole 120 is not used, the first end 132 of the earth engaging pole 130, may be secured directly to the base or frame of the EV charging station, electrical cabinet, or utility enclosure itself, such that the above-grade equipment is mounted directly onto the telescoping pole assembly without any intervening foundation structure. In such direct-mount embodiments, the first end 121 of the first pole 120 may be provided with a mounting flange, a threaded adapter, a sleeve receiver, or one or more bolt holes configured to mate directly with corresponding attachment features on the underside of the above-grade enclosure. This direct-mount configuration may be particularly advantageous in 1537833983.1applications where the above-grade equipment already includes its own integrated base enclosure or junction compartment, rendering a separate foundation box 110 unnecessary, or in lightweight or temporary installations where minimizing the number of components and overall system weight is desirable.

[0065] Referring to FIG. 10, in certain embodiments, the first pole 120, the earth engaging pole 130. or both, may be provided with one or more openings 138, apertures, slots, or knockouts formed through the wall of the respective pole at one or more locations along its length. These openings are configured to facilitate the passage of electrical conductors, data cables, conduit, or other utility lines into and out of the interior of the pole assembly, providing a direct and protected pathway for below-grade utility lines to transition from the buried conduit system into the interior of the foundation box 110 mounted at the upper end of the ground screw foundation system 100. This feature enables the ground screw foundation system 100 to serve as a functional conduit transition point at various installation depths, accommodating utility lines that may be present at different below-grade depths across different installation sites.

[0066] In some embodiments, the structural continuity of the ground screw foundation system 100 from the below-grade anchor point to the above-grade foundation box 110 further provides an effective electrical grounding path between the earth and the EV charging cabinet or utility enclosure mounted on the foundation box 110. In embodiments in which the poles and foundation box 110 are fabricated from electrically conductive materials, the ground screw foundation system 100 may function as a ground conductor, electrically bonding the mounted cabinet or enclosure to the earth without the need for a separate dedicated ground conductor.

[0067] The ground screw foundation system 100 is well-suited to both temporary and permanent installation configurations. In a temporary installation, the ground screw foundation system 100 is assembled and the earth engaging pole 130 is driven into the earth to the desired depth without any supplemental concrete or grouting. The ground screw foundation system 100 may subsequently be removed from the installation site by reversing the rotation of the earth engaging pole 130 to withdraw it from the earth, enabling the foundation and mounted equipment to be relocated to a new site with minimal effort and without damage to the installation site. This capability is a significant practical advantage of the ground screw' foundation system 100 relative to conventional concrete foundations, which cannot be relocated once placed.1637833983.1

[0068] In a permanent installation configuration, concrete or other grout material may be introduced into the annular space surrounding the earth engaging pole 130 below grade, filling the void between the pole and the surrounding soil and providing additional lateral support and resistance to uplift forces. In such embodiments, the exterior surface of the earth engaging pole, or the interior of the excavated or augered cavity surrounding it, may be configured to promote mechanical interlock with the surrounding concrete, further enhancing the structural integrity of the installed ground screw foundation system 100.

[0069] Because the earth engaging pole 130 is configured as a helical screw or auger, the ground screw foundation system 100 is self-digging in operation. Only a small pilot hole or starter excavation may be required at the installation site; the earth engaging pole 130 is then advanced into the earth by rotation using mechanical installation equipment, with the helical auger element 139 drawing the pole progressively downward into the soil until the foundation box 110 reaches the desired elevation at or flush with grade. In certain embodiments and site configurations, the foundation box 110 may alternatively be positioned above grade, resting on or elevated above the ground surface, to provide a raised mounting platform for the EV charging station or utility enclosure.

[0070] The earth engaging pole 130 and the first pole 120 can be fabricated from structural steel, including without limitation hot-rolled carbon steel, cold-drawn steel, galvanized steel, or stainless steel, selected to provide adequate tensile strength, yield strength, and toughness to withstand the installation loads imposed during driving and the sustained structural loads imposed by the mounted equipment during service. The specific grade and wall thickness of the pole material may be selected by the designer based on the applied loads, the soil conditions at the installation site, and the desired service life of the installation. In applications where the ground screw foundation system 100 is intended for long-term or permanent installation, higher-strength structural steel grades or enhanced corrosion-protection treatments are preferred.

[0071] Because the earth engaging pole 130 and at least a portion of the first pole 120 are disposed below7grade in direct contact with soil, groundwater, and other subsurface environmental contaminants, corrosion resistance is a critical performance requirement for the ground screw' foundation system 100. In preferred embodiments, the exterior surfaces of the earth engaging pole 130 and the first pole 120 are provided with one or more corrosion-resistant coatings or treatments, including without limitation hot-dip galvanization, electroplated zinc coating, epoxy powder coating, fusion-bonded epoxy lining, or thermoplastic coating, to protect the underlying metal substrate from oxidation 1737833983.1and electrochemical corrosion during below-grade service. In certain embodiments, the poles may be fabricated from inherently corrosion-resistant alloys, such as stainless steel or weathering steel, without the need for supplemental coating. The foundation box 110, which may be exposed to above-grade environmental conditions including precipitation, ultraviolet radiation, and temperature cycling, may similarly be fabricated from corrosionresistant materials or may be provided with a protective coating or finish suitable for outdoor above-grade service.

[0072] Because the foundation box 1 10 is installed at or near grade level and is exposed to precipitation, surface water runoff, and other environmental moisture sources, the management of water ingress into the interior of the foundation box 110 is an important design consideration for the ground screw foundation system 100. In certain embodiments, the foundation box 110 is configured as a fully sealed, watertight enclosure, in which all joints, seams, and conduit entry and exit openings are sealed using gaskets, sealant compounds, or other waterproofing means to prevent the ingress of water, dust, insects, and other environmental contaminants into the interior of the box. This fully sealed configuration is preferred in applications where the foundation box 110 houses sensitive electrical connections, terminal blocks, or other components that could be damaged by moisture exposure.

[0073] The interior surfaces of the foundation box 110 can include one or more internal mounting features to facilitate the installation of equipment, cable management hardware, and other accessories within the foundation box 110. In one embodiment, the foundation box 110 include a plurality of threaded inserts, tapped holes, or welded studs arranged in a standardized pattern on their interior faces, providing attachment points for mounting brackets, equipment shelves, cable trays, and cable management clips. In an alternative embodiment, the foundation box 110 includes integrated mounting rails or channels, such as DIN rails or slotted mounting channels, that extend horizontally or vertically along the interior face of the box and permit equipment and accessories to be slidably mounted and repositioned as needed. Cable management features such as cable tie anchor points, wire routing guides, and strain relief brackets may also be integrally formed or attached to the interior surfaces of the wall panels. The provision of internal mounting features enables the foundation box 110 to serve not merely as a structural support for the above-grade cabinet, but also as a functional below-grade equipment housing in which splicing equipment, junction boxes, grounding bars, surge protection devices, and other utility components may be securely mounted and organized.1837833983.1

[0074] In other embodiments, the foundation box 110 may be configured with one or more drainage apertures, weep holes, or drainage channels formed through the base or lower sidewalls of the box, which allow any water that enters the interior of the box to drain freely to the surrounding soil rather than accumulating within the box and creating a standing water condition that could promote corrosion of the interior components or create an electrical safety hazard. In such embodiments, the drainage apertures are preferably sized and positioned to facilitate gravity drainage of the interior while minimizing the ingress of soil, debris, or pests from below. In certain embodiments, a drainage layer of granular material, such as gravel or crushed stone, may be placed within the foundation box 110 below the electrical connection level to further facilitate drainage and to provide a clean bearing surface for the internal wiring and components. The choice between a sealed and a drained foundation box 110 configuration may be made by the designer based on the specific application, the local climate and precipitation conditions, and the applicable electrical code requirements for the installation.

[0075] The cross-sectional geometry of the earth engaging pole 130 and the first pole 120 is not limited to any particular shape, and may be selected by the designer based on the structural, functional, and manufacturing requirements of the specific application. In certain embodiments, the poles may have a circular or round cross-section, which is well-suited to fabrication by extrusion or seamless or welded tube manufacturing processes, and which provides isotropic bending stiffness in all transverse directions. In other embodiments, the poles may have a non-circular cross-section, including without limitation square, rectangular, hexagonal, octagonal, or other polygonal profiles. Non-circular cross-sectional profiles offer several practical advantages in the context of the ground screw foundation system 100. In particular, a polygonal cross-section such as a square or hexagonal profile provides flat engagement surfaces that can be readily engaged by standard mechanical drive tooling, such as a square or hex drive head or traditional wrenches, simplifying the installation process and reducing the need for specialized tooling.

[0076] Where the first pole 120 is slidably received within the earth engaging pole 130 in a telescoping relationship, the cross-sectional dimensions of the two poles are preferably selected to provide a close sliding fit that minimizes lateral play between the poles while still permitting smooth longitudinal adjustment throughout the full range of telescoping travel. In some embodiments, one or more bearing surfaces, wear pads, or low-friction liner materials may be interposed between the interior and earth engaging poles to reduce friction1937833983.1and wear during telescoping adjustment and to maintain alignment between the poles over the service life of the installation.

[0077] Referring to FIG. 13, in some embodiments, during installation of the ground screw foundation system 100, the earth engaging pole 130 is advanced into the earth by the application of rotational torque through mechanical installation equipment. That is, to facilitate the mechanical installation of the earth engaging pole 130 using powered installation equipment, the earth engaging pole 130 can be provided with a drive interface 150 at or near its first end 131 that is configured to be engaged by a complementary drive head or installation tool. In preferred embodiments, the drive interface 1 0 comprises a drive socket, drive recess, or drive head formed in or on the first end of the earth engaging pole, configured to be engaged by a hydraulic or electric rotary drive unit mounted on a skid steer loader, mini-excavator, or other mechanical installation equipment. The drive interface 150 may be configured as a square drive socket, a hex drive socket, a round drive collar with drive pin apertures, or any other drive geometry compatible with standard installation tooling used in the ground screw and helical pile installation industry.

[0078] In certain embodiments, the drive interface 150 may be integrally formed as part of the first end 131 of the earth engaging pole 130, for example by forming the first end of the pole with a hexagonal or square external profile that can be received directly into a complementary hex or square drive socket on the installation equipment. In other embodiments, the drive interface 150 may comprise a separate drive adapter or drive head that is temporarily attached to the first end of the earth engaging pole 130 for the duration of the installation process and removed after the earth engaging pole 130 has been advanced to the desired below-grade depth. The drive adapter may be secured to the earth engaging pole 130 by a threaded connection, a bolted flange connection, or a keyed or pinned connection, and is preferably designed to transmit the full installation torque from the drive equipment to the earth engaging pole 130 without slippage or structural failure. In preferred embodiments, the drive interface 150 is further configured to be compatible with torque measurement devices or torque indicators that allow the installer to monitor the installation torque in real time as the earth engaging pole 130 is advanced into the ground, providing a direct indication of the soil bearing capacity and the adequacy of the below-grade anchorage as installation proceeds.

[0079] In embodiments where the first pole 120 and the earth engaging pole 130 have complementary non-circular cross-sections, such as square or hexagonal profiles, the engagement between the flat side walls of the respective poles inherently resists relative 2037833983.1rotation, providing an effective anti-rotation function without the need for additional mechanical features. In embodiments where the poles have circular cross-sections, dedicated anti-rotation features are preferably provided, including without limitation one or more longitudinal keys or splines formed on the outer surface of the first pole 120 that engage corresponding keyways or spline grooves formed on the inner surface of the earth engaging pole, or one or more anti-rotation pins, tabs, or projections that extend radially from the first pole 120 and engage corresponding slots or recesses in the earth engaging pole. These anti-rotation features allow the first pole 120 to slide longitudinally within the earth engaging pole 130 for telescoping adjustment while preventing relative rotation between the two poles under applied torsional loads. In embodiments in which the foundation box 110 is secured to the top of the pole assembly prior to installation, the foundation box 110 may additionally serve as a torque reaction point, with the installer holding the foundation box 110 stationary while the earth engaging pole 130 is rotated into the ground, further preventing unintended rotation of the first pole 120 and foundation box 110.

[0080] The ground screw- foundation system 100 is designed to resist the full range of structural loads that may be imposed on the mounted EV charging station, electrical cabinet, or utility- enclosure during normal service, including vertical compressive loads arising from the self-weight of the mounted equipment, lateral loads arising from wind pressure, incidental vehicle impact, or vandalism, and uplift loads arising from wind or from the mechanical engagement of the helical auger element with the surrounding soil during extraction. The structural adequacy of the ground screw foundation system 100 for a given application is a function of the soil bearing capacity- at the installation site, the geometry and embedment depth of the earth engaging pole, the cross-sectional dimensions and material properties of the pole assembly, and the magnitude and direction of the applied loads.

[0081] In preferred embodiments, the earth engaging pole 130 is designed and sized to achieve a minimum embedment depth and a minimum auger element diameter that provide the required axial and lateral load capacity in the anticipated range of soil conditions at the target installation sites, with an appropriate factor of safety against foundation failure. The telescoping connection between the first pole 120 and the earth engaging pole 130 is designed to transmit the full range of applied loads from the first pole 120 to the earth engaging pole 130 and thence to the surrounding soil, without yielding, buckling, or other structural failure of the connection under design load conditions. The locking elements that secure the first pole 120 in position relative to the earth engaging pole 130 are hkeyvise 2137833983.1designed to carry the shear loads imposed by the applied lateral and uplift forces without failure or loosening during service. In applications where the ground screw foundation system 100 is subject to unusually high lateral loads, such as installations in high-wind-exposure locations or locations subject to vehicular traffic, the structural performance of the system may be further enhanced by the introduction of concrete backfill around the earth engaging pole 130 below grade, as described above, or by the use of multiple earth engaging poles arranged in a cluster configuration to distribute the applied loads among multiple below-grade anchor points. For example, a foundation box 1 10 can be secured to a plurality of first poles across a larger area, to spread the load across a greater area and foundation.

[0082] Referring to FIG. 14, in a typical installation 300 of the ground screw foundation system 100 for an EV charging station or enclosed utility cabinet, the installer first identifies the desired location at the installation site and, if necessary, excavates a small pilot hole 310 or starter depression in the ground surface at the point where the earth engaging pole 130 is to be installed. The installer then positions the second end 133 of the earth engaging pole 130 at the pilot hole and engages the drive interface at or near the first end 132 of the earth engaging pole 130 with a hydraulic or electric rotary drive unit mounted on a skid steer loader, mini-excavator, or equivalent mechanical installation equipment. The installer applies rotational torque to the earth engaging pole 130, causing the helical auger element 131 to engage the surrounding soil and draw the earth engaging pole 130 progressively downward into the earth 320. The installer monitors the installation torque and the depth of the earth engaging pole 130 as it advances, continuing to drive the earth engaging pole 130 until it has reached the desired below-grade depth corresponding to the site-specific trench and conduit configuration. Once the earth engaging pole 130 is fully installed, the drive adapter or drive head, if used, is removed from the first end 132 of the earth engaging pole 130 to expose the opening 134. The installer then inserts the second end 122 of the first pole 120 into the opening 134 at the first end 132 of the earth engaging pole 130, and slides the first pole 120 downward into the earth engaging pole 130 until the first pole 120 reaches the desired extension height 330, at which the first end 121 of the first pole 120 projects above grade at the elevation necessary to support the foundation box 110 at or flush with the finished grade. The installer then locks 340 the first pole 120 with respect to the earth engaging pole 130. engages the locking elements 135, such as thumb screws, locking pins, or bolts, through the locking apertures 136 in the earth engaging pole 130 and, where provided, the corresponding engagement features 123 in the first pole 120, thereby fixing the first pole 120 in position relative to the earth engaging pole 130. With the telescoping 2237833983.1pole assembly secured, the installer next attaches 350 the foundation box 110 to the first end 121 of the first pole 120 using the pole mounting element 114, whether by threaded engagement, slip-fit connection with fastening bolts, or other suitable means as described herein, and verifies that the foundation box 110 is level using the angular adjustment features of the pivotable connector or pole-to-box interface, if provided. The installer then routes 360 the below-grade electrical conduit and conductors through the utility openings 138 in the pole assembly and into the interior of the foundation box 110, making all necessary electrical connections, splices, and terminations within the foundation box 110 in accordance with the applicable electrical code requirements. Where a permanent installation is desired, the installer may introduce concrete or grout 370 into the annular space surrounding the earth engaging pole 130 below grade and allow it to cure before proceeding. Finally, the EV charging station, electrical cabinet, or utility enclosure is installed 380: positioned on the mounting platform 111 of the foundation box 110, secured to the foundation box 110 using the appropriate mounting hardware and bolt pattern, and connected to the electrical conductors terminated within the foundation box 110, completing the installation of the fully operational EV charging station or utility cabinet on the ground screw foundation system 100.

[0083] Having thus described several aspects of at least one example, it is to be appreciated that various alterations, modifications, and improvements will readily occur to those skilled in the art. For instance, examples disclosed herein can also be used in other contexts. Such alterations, modifications, and improvements are intended to be part of this disclosure and are intended to be within the scope of the examples discussed herein. Accordingly, the foregoing description and drawings are by way of example only.

[0084] Also, the phraseology and terminology’ used herein is for the purpose of description and should not be regarded as limiting. Any references to examples, components, elements or acts of the systems and methods herein referred to in the singular can also embrace examples including a plurality, and any references in plural to any example, component, element or act herein can also embrace examples including only a singularity. References in the singular or plural form are not intended to limit the presently disclosed systems or methods, their components, acts, or elements. The use herein of “including,” “comprising,” “having,” “containing,” “involving,” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. References to “or” can be construed as inclusive so that any terms described using “or” can indicate any of a single, more than one, and all of the described terms. In addition,2337833983.1in the event of inconsistent usages of terms between this document and documents incorporated herein by reference, the term usage in the incorporated references is supplementary to that of this document; for irreconcilable inconsistencies, the term usage in this document controls.2437833983.1

Claims

What is claimed is:

1. A foundation system, comprising:a first pole comprising a first end, a second end, and a middle portion connecting the first end and second end;a second pole comprising a first end, a second end, and a middle portion connecting the first end and the second end, wherein at least a portion of the second pole comprises an external helical screw element configured to engage surrounding soil when the second pole is rotated into the earth, and wherein the first end of the second pole defines an opening configured to receive the first pole;the first pole is configured to be adjustably disposed within the second pole; at least one locking element configured to fix the relative position of the first pole with respect to the second pole; anda foundation box connected to the first end of the first pole.

2. The foundation system of claim 1, wherein the second pole compnses one or more locking apertures formed through a wall of the second pole.

3. The foundation system of claim 2, wherein the at least one locking element comprises a thumb screw, a machine screw, a bolt, a locking pin, or a spring-loaded detent pin received through the one or more locking apertures to engage the first pole.

4. The foundation system of claim 2, wherein the first pole comprises one or more engagement features positioned along its length and configured to cooperate with the at least one locking element.

5. The foundation system of claim 1, wherein the first pole comprises a retention feature at or near its second end configured to prevent the first pole from being withdrawn entirely from the second pole.

6. The foundation system of claim 5, further comprising a biasing element within the second pole.2537833983.

17. The foundation system of claim 1, wherein the first pole and the second pole are connected through a threaded engagement.

8. The foundation system of claim 1, further comprising one or more interior poles nested within the second pole.

9. The foundation system of claim 1, wherein the first pole, the second pole, or both, comprise one or more openings formed through a wall thereof.

10. The foundation system of claim 1, wherein the first pole and the second pole are configured to provide an electrical ground path between the earth and an electrical cabinet, an EV charging station, or an utility enclosure.

11. The foundation system of claim 1, wherein the foundation box is secured to the first end of the first pole by a pole mounting element comprising a threaded connection, a slip-fit engagement secured by fastening screws or bolts, or a ratcheting system that tightens around the first end of the first pole.

12. The foundation system of claim 1, wherein the foundation box comprises a base, a plurality of sidewalls defining an interior cavity’, and a removable mounting platform secured to the base and sidewalls, the mounting platform configured to provide a mounting surface for an electrical cabinet, an EV charging station, or an utility enclosure.

13. The foundation system of claim 1, wherein the foundation box comprises one or more conduit entry and exit openings formed through the sidewalls or the mounting platform of the foundation box.

14. The foundation system of claim 1, wherein the foundation box is configured to be interchangeably connectable to the first pole and the second pole.

15. The foundation system of claim 1, wherein the first pole and the second pole have complementary non-circular cross-sections.2637833983.

116. The foundation system of claim 1, wherein at least one of the first pole and the second pole is provided with a corrosion-resistant coating or treatment comprising hot-dip galvanization, electroplated zinc coating, epoxy powder coating, fusion-bonded epoxy lining, or thermoplastic coating.

17. A method of installing a foundation system for an above-grade electrical cabinet, EV charging station, or utility enclosure, comprising:driving a second pole into the earth at an installation site by applying rotational torque to the second pole, the second pole having a first end with an opening, a second end, and at least a portion comprising an external helical screw element that engages surrounding soil as the second pole is rotated;inserting a first pole into the opening at the first end of the second pole after the second pole has been advanced to a desired below-grade depth;adjusting the first pole relative to the second pole to a predetermined height; securing the first pole in position relative to the second pole at the predetermined height using at least one locking element; andmounting a foundation box to a first end of the first pole.

18. The method of claim 17, further comprising introducing concrete or grout material into an annular space surrounding the second pole below grade.2737833983.1

Images